Method and apparatus for refinement of organic material

ABSTRACT

A method and an apparatus for the refinement of organic material is disclosed. Converting and processing organic material is achieved with or without organic and inorganic additions. The base material uses waste material, i.e. forest industry waste and slaughter-house waste. The method and apparatus produce a packeted end product, specifically carbon powder/granulate as full and charcoal for grilling/smoking, as well as active coal and additives for steel production.

FIELD OF THE INVENTION

The present invention relates to a method and an apparatus forrefinement of organic material. More specifically, the present inventionrelates to converting and processing of organic material, with orwithout organic and inorganic additions. The base material utilized iswaste from other production, e.g. from the forest industry orslaughter-house waste. The invention provides for refinement of thewaste material into directly useful or packeted end product where thewaste is produced. The invention comprises carbonization of the wastematerial into carbon powder, and subsequent treatment of the carbonpowder into various forms. The invention specifically produces carbonpowder/granulate as fuel, charcoal for grilling/smoking, active coal,additives for steel production etc.

State of the Art

Various carbonization and charcoal burning methods have been known for along time. The problem is to find a method which can be carried out to alower cost, since the waste material has a very short range of action,i.e., it is not worthwhile to transport the waste material a longerdistance than e.g. 50 km. On the other hand, coal from coal mines iscontaminated by sulphides and thus requires expensive purification byfilters etc.

The present invention provides a dynamic system which can be transportedto the origin of the waste material and which at low cost refines theorganic material. Thus, organic materials, such as agricultural, forestand slaughterhouse waste, can be used, which materials are notcontaminated by undesired substances.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a method of refinement oforganic material characterized by the steps of:

feeding finely divided base material of organic origin into a closedreactor;

decomposing the base material into carbon powder and reaction fluids bycarbonization in said reactor;

cooling the carbon powder; and

forming the carbon powder to the desired particle size.

Advantageously the cooling step further includes additional treatment ofcarbon powder, such as mixing with organic and/or inorganic materials inorder to produce various end products. The invention is especiallyintended for producing charcoal for grilling/smoking, active coal andcarbon powder/granulate as fuel.

The invention also provides an apparatus for carrying out the method ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example and withreference to the appended drawings, in which:

FIG. 1 is a schematic view of an exemplary apparatus according to theinvention;

FIG. 2 is a more detailed embodiment of the invention;

FIGS. 3, 4 and 5 are different views of the reactor of the invention;

FIG. 6 is a cross-sectional view of a heating chamber;

FIGS. 7A and 7B are elevation and plan views, respectively, of a firstembodiment of a cooling unit according to the invention;

FIG. 7C is a sectional view of the cooling unit of FIGS. 7A and 7B; and

FIGS. 8A and 8B are elevation and plan views, respectively, of a secondembodiment of a cooling unit according to the invention.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

The term refinement, as used herein, refers to conversion and processingof the chemical, biological and physical structure of the organicmaterial (the biomass, carbon compounds), with or without organic orinorganic additions. The intention is to use excess and wastebiomaterial and to obtain new end products by multiplicative processeffect. Suitable base materials are most organic materials but the mostoptimal are: air-moist wood, forest fuel or energy wood, chips, peat,oilshale, dried animal debris, straw etc. By supplying heat energy at alow pressure, which promotes the decomposition of the material, theconversion process is effected, with or without additions, whereupon, independence of the structure of the biomass, such as energy content,microstructure, elemental analysis, microsystems, main and by-productsare formed in different stages. The most important main products areconcentrated carbon compounds and condensed distillates in the form oftar, turpentine oil, methanol, acetic acid etc. The by-product isuncondensable gas, which is used to partly fuel the system as processenergy. The main products are treated further to end products. Organicmaterial can also be treated in the same apparatus without causingchemical conversion of the structure, with or without additions or heatin the right combination, such as disinfection, product forming, etc.

In FIG. 1 a preferred embodiment of the invention is shown in aschematic representation. The apparatus comprises a pre-drying unit A, aprocess unit or reactor B, a cooling unit C, and granulation unit D, anafter-treatment unit E and a distillation unit F. Heating units G areprovided before the pre-drying unit A and the process unit B.

In the pre-drying unit A, if necessary, the base material is dried sothat it gets a water content of 5 to 10 percent. The base material isalso pre-heated to 130°-170° C. If the base material permits, the systemcan be used without the pre-drying unit A. The base material isthereafter fed into the process unit B in which a high-temperaturecarbonization process is effected. The process unit is possibly alsoprovided with a graphitization zone. The process yields carbon powderand various fluids. The fluids are directed to the distillation unit F,in which distillation is carried out. The distillation by-products areoutput at H and the non-condensable gases are output at I andreintroduced into the system at the heating units for energy recovery.

The carbon powder is temporarily stored and cooled in the cooling unitC, where the carbon powder can be treated by addition of organic and/orinorganic materials.

The cooling unit C yields the primary end product, which is fed into thegranulation unit D, where it is formed to granulate of a desiredparticle size. This is the secondary end product.

In the after-treatment unit E the granulate is cooled further, sortedand possibly packeted to yield a finished end product.

The process unit B is also provided with an outlet J for flue gases.

In FIG. 2 a specific embodiment of the present invention is shown by wayof example. The base material is ground, chopped, sawed or otherwisedivided into pieces of an appropriate particle size. It is importantthat the pieces are not too big, since this disadvantageously effectsthe heat absorption of the material. The finely divided base material isfed by a feeding unit 1, e.g. a conveyor belt or a screw feeder, intothe pre-drying unit 2. In the pre-drying unit the water contained in thebase material is evaporated so that the base material obtains a watercontent of about 5 to 10 percent, the dryer the better.

The material is then fed to the reactor 7 by the reactor feeding unit 6,a screw feeder. The material is degassed by compressing the material inorder to avoid oxidation. The reactor 7 is described in further detailbelow. The reactor is heated to a temperature of 800°-900° C. Thetemperature is achieved mainly by heat from a burner 21 together withheat set free from exothermic reactions. The burner 21 is fuelled oiland combustible gases recovered from the process. The pressure in thereactor can be varied from about 5/100 atm to 3 atm. A low pressurepromotes the decomposition of the material. The base material isdecomposed into carbon powder, the primary end product, and variousfluids. The carbon powder has a particle size of about 1 μm. The carbonpowder is the product of primary interest but the by-product fluids areutilized as well. Two valves 23 are operated to evacuate the gaseousphase through a conduit 24 to a distillation unit (not shown). Theconduit 24 has two connections to the reactor 7, one at each side of thereactor. By closing one of the valves 23 the associated portion of theconduit 24 can be cooled to prevent it from overheating. Combustiblegases are transported from the distillation unit to a vessel 22 fortemporary storage. From the vessel 22 the gases are fed to a burner 21that heats the reactor 7 which is arranged in an isolating chamber 9 tobe described in further detail below. Thus, the non-condensable gasesare reintroduced into the system for energy recovery.

Thereafter the carbon powder is brought to a cooling unit 10 in whichthe carbon powder is cooled and possibly treated by addition of organicor inorganic material, in dependence of the intended secondary endproducts. The temperature is decreased from 900° to about 60° C. Fromthe cooling unit 10 the secondary product is transported by a cyclone11, 12 to a buffer storage 13 in which the product is cooled further, ifnecessary. Two embodiments of the cooling unit are described in furtherdetails below.

Thereafter the secondary product is formed in a forming or granulationunit 15 in which the product is granulated to a desired particle size.The product is now ready for immediate use, bulk transport or packetingin a packeting unit (not shown).

In FIGS. 3 to 5 various views of the reactor 7 are shown. The reactor ismade of an acid-resistant material in order to be able to resist thereactive products of the carbonization. The reactor has an inlet 31through which the base material is continuously fed. The carbonizedmaterial is output through an outlet 32. The reactor is rotated by amotor 8 (shown in FIG. 2). The motor speed can be varied in at leastthree steps in dependence of the base material and the various processparameters. A plurality of fins 33 arranged around the inlet 31 and fins35 arranged radially on the interior surface of the reactor serve todistribute the material as the reactor is rotating. A coil arrangementcollects the carbon powder produced by the process and feeds thematerial out of the reactor 7 through the outlet 32.

In FIG. 6 the heating chamber 9 is shown in a cross-sectional view. Thechamber actually consists of two chambers, a small combustion chamber 61and a larger chamber 62 housing the reactor 7. The combustion chamber 61has walls provided with slabs 63 of ceramic material for heat isolation.The ceramic slabs are quite heavy and they are attached by means ofhooks 64 which prevent the slabs from coming loose due to vibrationswhen the apparatus is transported. The reactor chamber 62 is isolated bywalls of fiberglass in order to keep down the weight of the chamber. Thetop portion of the chamber 62 is hinged as a lid, so that it can beswinged aside for removal or repairing of the reactor 7.

In FIGS. 7A, 7B and 7C a first embodiment of the cooling unit 10'according to the invention is shown. As is best seen in FIG. 7C, thecooling unit comprises a trough-like portion 71 having an enclosing topportion or cover 72. The material to be cooled is fed into the inlet 73and conveyed through the unit to the outlet 74 at the other end. Thematerial is moved by vibrating the whole unit by means of a vibratingmotor 75 attached to one of the longitudinal sections 76. Eachlongitudinal section 76 has a cooling circuit 77 for circulating coolingfluid, e.g. water or oil. The number of sections 76 is chosen independence of the required dwelling time of the material. Also thefrequency and direction of the strokes of the motor can be varied.

The cooling fluid is circulated in the trough portion 71 and also inupright flanges 78 provided on the bottom of the trough. Thus, thematerial has a large contact surface with the cooling portions.

The cooling unit 10' is also utilized to add organic and/or inorganicmaterial to the carbon powder and/or to activate the carbon powder. Aplurality of nozzles (not shown) is provided through the cover 72.Gases, such as CO₂ and H₂ O, and/or other additives are injected intothe carbon powder which stirs up the powder and thus assists to bringthe powder in contact with the cooling portions. In addition, theinjection itself has a cooling effect and the CO₂ also preventsauto-ignition of the carbon powder.

In FIGS. 8A and 8B a second embodiment of the cooling unit 10" is shownin two views. It comprises a double-walled tube 81 which houses a shaft82 provided with flanges 83. The carbon powder to be cooled isintroduced into the inlet 84 and moved through the unit to the outlet 85at the other end thereof. At the edge of each flange 83 vanes 86 whichare shaped like on a propeller are provided. When the shaft 82 isrotated by a motor 87 the carbon powder is moved successively from oneflange 83 to the next through the whole unit.

The cooling fluid, e.g. water or oil, circulates between the doublewalls of the tube 81 as well as in the shaft 82 and the flanges 83. Thisarrangement provides a large contact surface between the cooling unitand the carbon powder.

The cooling fluid is introduced into the shaft 82 through a rotary flowcontrol joint 88 provided at one end of the unit. The joint comprises adouble-walled tube. The cooling fluid enters the shaft 82 through theinner tube and is directed to the outer tube 81 by a similar joint atthe other side of the unit. The cooling fluid finally exits through theouter annulus of the joint 88.

The cooling unit 10" is also provided with nozzles (not shown) forinjecting organic and/or inorganic material into the carbon powder. Theinjection is effected in a similar way to the first embodiment of thecooling unit.

The apparatus according to the invention is suitable for producingvarious products which are obtained by varying the process parameters,especially the temperature and the pressure in the reactor 7 and byvarying the organic and/or inorganic additives. The first product ischarcoal for grilling and/or smoking. In this case the carbon powder inthe cooling unit is mixed with sawdust from different kinds of wood,spices, water and/or fat. The charcoal so produced generates differentkinds of smoke when burning and thus, conveys different seasoning of thegrilled or smoked foodstuff. The particle size is about 10 mm diameter.

The second product is active coal in which case carbondioxide, watersteam and/or some other activating agent are injected into the carbonpowder during the cooling in the cooling unit in order to open the poresof the carbon particles.

The third product is pure carbon powder which is required e.g. in thesteel industry and pharmaceutical industry.

A fourth product is graphite. Graphite production requires hightemperature and pressure which accordingly require a high strengthreactor. This may be prohibitive for the mobility of the system.

The apparatus is advantageously mounted on a vehicle (not shown) so thatit readily can be transported to where the base material is produced.Thus, the high transport costs of moving the cheap base material areeliminated. These costs, prior to the present invention, have beenprohibitive.

In summary, the present invention has several advantages over the priorart. The biomass is continously fed through the closed, dynamic system,wherein the internal and external parameters of the material and theclimate are controlled. The temperature, pressure, dynamic conditions,chemical environment--if necessary by addition of organic or inorganicmaterials--are correctly set. Starting energy is supplied. At theworking temperature/pressure the conversion process is effected,periodically in different stages and rates. Energy is generated whichcan be reused. Through process control the quantity-quality relation canbe set as desired between main and by-products and can be varied byadditional substances. The biomass can also be treated withoutstructural conversion. The primary end product--or the base material ofthe secondary end product--is fed into a buffer storage, agitated atslowly decreasing temperature in a determined period and rate. The endstage of the production is the production of the secondary end productthrough granulation, compression, extrusion, pulverization, moulding,sorting, or any other type of treatment, at a suitable temperature withor without agents added. The packeting is prepared and the finishedmaterial is cooled, dried, dusted, sorted, either in situ or during thebulk transport. The material being finished, the material may optionallybe directly packeted in a small unity box system for direct deliverywithout risk of self-reaction and transport damages.

On the basis of vegetable biomass carbon powder, charcoal and othertypes of high class fuels with pre-determined energy content, carbonfilter systems, catalysators, etc. are produced. On the basis of animalbiomass, additional material for fodder, manure, etc. are produced.General disinfection of biomass with or without additions can beobtained. That is, the system according to the invention can be utilizedwith the purpose only to disinfect organic material, e.g. infected wastefrom hospitals. In this case, the end product is of minor interest justas long as it is not dangerous to handle with respect to the risk ofinfection. General processing of organic material to convert thestructure of the biomass, add, combine, subtract organic or inorganicmaterial can be achieved.

I claim:
 1. Method of refinement of organic material including the stepsof:a) continuously feeding finely divided base material of organicorigin into a reactor of a closed dynamic system under low pressure of0.05 atm; b) rotating the reactor and heating it to a temperature of800°-900° C.; c) decomposing the base material into carbon powder andreaction fluids by carbonization in said reactor and separating thegaseous phase in one step; d) cooling the carbon powder in a coolingunit comprised in the closed dynamic system with indirect contact onlywith a cooling medium.
 2. Method according to claim 1, wherein thecooling step further includes injecting an activating agent such as CO₂or H₂ O into the carbon powder in order to produce active coal. 3.Method according to claim 1, wherein the end product treatment stepfurther includes mixing the carbon powder with sawdust, spices, waterand optionally fat, said method producing a particle size appropriatefor charcoal for the grilling or smoking of foodstuffs.
 4. Apparatus forrefinement of organic material, including:a feeding means for feedingfinely divided organic base material into a closed dynamic processingmeans; the processing means having a rotating reactor under low pressureof 0.05 atm, said reactor being acid resistant and including at least acarbonization zone for producing carbon powder; the reactor beingprovided with fins arranged round an inlet of the reactor and finsarranged radially on the interior surface of the reactor, said finsserving to distribute the material as the reactor is rotating; a coilarrangement arranged at an outlet of the reactor for assisting thetransportation of material out of the reactor; two valves positioned oneat each end of the reactor and capable of being opened alternatively forevacuating a gaseous phase including any cumbustible gases; a motorhaving variable speed for rotating the reactor; an external heatingmeans for heating the material in the reactor to a temperature of800°-900° C., said heating means being connected for burning saidcombustible gases; and a cooling means for cooling the carbon powder. 5.Apparatus according to claim 4, characterized by a mixing means formixing the carbon powder after or during the cooling with sawdust,spices, water and optionally fat in order to produce charcoal for thegrilling or smoking of foodstuffs as end product treatment.
 6. Apparatusaccording to claim 4 or 5, characterized in that an injecting means forinjecting activating agents such as CO₂ or H₂ O steam into the carbonpowder is provided in connection with the cooling means in order toproduce active coal as end step for the carbon production.
 7. Apparatusaccording to claim 4, wherein it is arranged on a mobile vehicle. 8.Apparatus according to claim 4, wherein the cooling means comprises:adouble-walled tube; a hollow shaft having a plurality of flangesprovided with vanes at the respective edges thereof; an inlet at one endof the tube and an outlet at the other end thereof; a motor for rotatingthe shaft, so that the carbon powder is moved through the tube from theinlet to the outlet by the vanes; a cooling circuit provided through theshaft and the flanges for circulating cooling fluid in one direction ofthe unit, and back through the interior of the double-walled tube in theopposite direction.
 9. Charcoal produced according to anyone of claims1, 2 or 3 for the grilling or smoking of foodstuffs, wherein in additionto pure carbon, said charcoal also contains sawdust, spices, water andoptionally fat.